New: ext3 I/O errors when <4096 blocksize on certain hardware

http://bugzilla.kernel.org/show_bug.cgi?id=11564

Summary: ext3 I/O errors when <4096 blocksize on certain hardware
Product: File System
Version: 2.5
KernelVersion: 2.6.27
Platform: All
OS/Version: Linux
Tree: Mainline
Status: NEW
Severity: normal
Priority: P1
Component: ext3
AssignedTo: [email protected]
ReportedBy: [email protected]

Latest working kernel version:2.6.17
Earliest failing kernel version:2.6.18
Distribution:Mandriva, OpenSUSE
Hardware Environment: PIII-700 on i440BX (100FSB Tyan S1846) piix/sym53c8xx (SYM8751SP)
dysfunctional HD: Quantum Atlas III QM39100TD-SW Rev: N1B0
OK HD: IBM DPSS 309170; 07N3120; MLC: PS0S96 (Ultrastar)
OK HD #2: 60G Seagate Barracuda PATA on piix
Software Environment:typical, except all partitions formatted ext3 -I128 & -b1024 or -b2048 due to their small size (4.8G or less)
Problem Description:
Tail of most recent (Factory 2.6.27-rc6) /var/log/messages:

Sep 13 21:29:23 xxxxx kernel: sd 0:0:1:0: [sda] Result: hostbyte=DID_SOFT_ERROR
driverbyte=DRIVER_OK,SUGGEST_OK
Sep 13 21:29:23 xxxxx kernel: end_request: I/O error, dev sda, sector 1810985
Sep 13 21:29:23 xxxxx kernel: sd 0:0:1:0: [sda] Result: hostbyte=DID_SOFT_ERROR
driverbyte=DRIVER_OK,SUGGEST_OK
Sep 13 21:29:23 xxxxx kernel: end_request: I/O error, dev sda, sector 1811039
Sep 13 21:29:23 xxxxx kernel: JBD: Detected IO errors while flushing file data
on sda7
Sep 13 21:29:23 xxxxx kernel: JBD: Detected IO errors while flushing file data

on sda7

Similar errors occur with other post-2.6.17 kernels. Typical result is rpm database corruption (see e.g. https://qa.mandriva.com/show_bug.cgi?id=32547 not reported by me) making system very difficult to use.

I've run current Cookers on this hardware combination for several years, but just over a year ago started having trouble when the 2.6.17 kernel was upgraded. I ran the manufacturer's QDPS diagnostics on the Quantum shortly after the problem appeared about 13 or so months ago, and again a few days ago, both times OK according to QDPS. I ran the LSI controller's format program on it a few days ago too. I then tried installing fresh Mandriva 2007.1 (complete success) and OpenSUSE 10.2 (limited number of errors of this type). Trying to do a current install of Cooker or Factory are hopeless. I tested Factory by copying a Factory/11.0 installation from the PATA to sda7 on SCSI, then trying to update to current Factory, while Cooker was on sda7 for several years. The problem simply did and does not exist with the Mandriva 2.6.17 and old kernels using the Atlas III. I tried cloning the Atlas III to the Ultrastar, and cannot reproduce using either the Barracuda or the Ultrastar. Trying a different SCSI cable didn't help.

Steps to reproduce:
Try to use a wrong hardware combination.

Quoted 11 lines · On Sat, 13 Sep 2008 19:20:35 -0700 (PDT) [email protected] wrote:

http://bugzilla.kernel.org/show_bug.cgi?id=11564
Tail of most recent (Factory 2.6.27-rc6) /var/log/messages:

Sep 13 21:29:23 xxxxx kernel: sd 0:0:1:0: [sda] Result: hostbyte=DID_SOFT_ERROR
driverbyte=DRIVER_OK,SUGGEST_OK
Sep 13 21:29:23 xxxxx kernel: end_request: I/O error, dev sda, sector 1810985
Sep 13 21:29:23 xxxxx kernel: sd 0:0:1:0: [sda] Result: hostbyte=DID_SOFT_ERROR
driverbyte=DRIVER_OK,SUGGEST_OK
Sep 13 21:29:23 xxxxx kernel: end_request: I/O error, dev sda, sector 1811039
Sep 13 21:29:23 xxxxx kernel: JBD: Detected IO errors while flushing file data
on sda7
Sep 13 21:29:23 xxxxx kernel: JBD: Detected IO errors while flushing file data

Quoted 1 line

on sda7

Quoted 8 lines

Similar errors occur with other post-2.6.17 kernels. Typical result is rpm database corruption (see e.g. https://qa.mandriva.com/show_bug.cgi?id=32547
not reported by me) making system very difficult to use.

The problem simply did and does not exist with the
Mandriva 2.6.17 and old kernels using the Atlas III. I tried cloning the Atlas III to the Ultrastar, and cannot reproduce using either the Barracuda or the Ultrastar. Trying a different SCSI cable didn't help.